PRODUCTION OF POLYPROPYLENE FROM RENEWABLE RESOURCES

• US 20100069589A1
• Filed: 11/23/2009
• Published: 03/18/2010
• Est. Priority Date: 05/23/2007
• Status: Active Grant

• Current Assignee: David Bradin
• Original Assignee: David Bradin
• Inventors: Bradin, David
• Granted Patent: US 8,916,661 B2
• Time in Patent Office: Days
• US Class Current: 526/170
• CPC Class Codes: C07C 11/06 Propene
• CPC Class Codes: C07C 6/04 at a carbon-to-carbon double bond
• CPC Class Codes: C08F 110/06 Propene
• CPC Class Codes: C08F 210/08 Butenes
• CPC Class Codes: C08F 210/16 Copolymers of ethene with alpha-alkenes, e.g. EP rubbers

Abstract

Processes for forming low molecular weight (C_2-4) olefins from renewable resources, and polyolefins formed from the olefins, are disclosed. The C_2-4 olefins are produced by first converting a renewable resource, capable of being converted to syngas, to syngas. The syngas is converted, using Fischer-Tropsch synthesis using a catalyst with low chain growth probabilities, to a composition comprising C_2-4 olefins, which are then isolated to form a C_2-4 olefin-rich stream. Propylene can be isolated from this stream, and the ethylene and butylene can be subjected to olefin metathesis to produce additional propylene. The propylene, or other olefins, can be subjected to a variety of polymerization conditions and used in a variety of products, to replace the propylene, and polypropylene, produced from crude oil. Thus, the olefins, and polymers, copolymer and terpolymers thereof, can help reduce U.S. dependence on foreign crude oil.

Claims

1. A process for producing propylene from renewable resources, comprising the steps of:

a) converting one or more renewable resources capable of being converted to syngas into syngas, b) using the syngas in a Fischer-Tropsch reaction using a catalyst with low chain growth probabilities to obtain a product stream that includes C_2-4 olefins, and, optionally, C_2-4 paraffins, c) isolating at least a portion of the propylene, optionally along with propane, d) separately isolating ethylene and butylene, optionally along with ethane and butane, e) performing olefin metathesis on the ethylene and butylene, to obtain an olefin metathesis product stream rich in propylene, f) isolating the propylene from the olefin metathesis product stream, and g) combining the propylene originally obtained during the Fischer-Tropsch synthesis with the propylene obtained from the olefin metathesis step.

2. The process of claim 1, wherein the renewable resource is selected from the group consisting of glycerol, methanol, lignin, black liquor, switchgrass, bagasse, corn stover, rice hulls, sawdust, wood, hemicellulose, and algae.

3. The process of claim 1, wherein at least a portion of the C_2-4 paraffins, or a fraction thereof, is dehydrogenated to form olefins.

4. The process of claim 3, further comprising isolating propylene from the dehydrogenated C_2-4 paraffins.

5. The process of claim 3, wherein at least a portion of the resulting olefins are subjected to olefin metathesis to form propylene, further comprising isolating the propylene.

6. The process of claim 1, further comprising polymerizing the propylene to form polypropylene.

7. The process of claim 1, further comprising copolymerizing the propylene with another monomer to form a polypropylene copolymer.

8. The process of claim 7, wherein the other monomer is selected from the group consisting of ethylene, butylene, maleic acid, and furan.

9. The process of claim 6, wherein the polymerization is performed using a Ziegler-Natta catalyst.

10. The process of claim 6, wherein the polymerization is performed using a metallocene catalyst.

11. A process for preparing a C₃ product stream from a feedstock including predominantly C₂ and C₄ olefins and paraffins, comprising the steps of:

a) contacting a C₂ and 0₄ olefin and paraffin-containing feedstock with a catalyst which includes a hydrogenation/dehydrogenation catalyst and an olefin metathesis catalyst under conditions which dehydrogenate the paraffins to olefins, and metathesize the olefins, to provide a product stream, b) isolating a C₃-olefinic fraction from the product stream, wherein the initial C₂ and C₄ olefin and paraffin-containing feedstock is obtained, at least in part, from the conversion of biomass or other renewable materials to syngas, the conversion of the resulting syngas, via Fischer-Tropsch synthesis to a C_2-4 olefin/paraffin product stream, with at least partial removal of the C₃ olefins and, optionally, paraffins from this stream, to produce a product stream comprising C₂ and C₄ olefins and paraffins.

12. A process for producing polyolefins from renewable resources, comprising the steps of:

a) converting one or more renewable resources capable of being converted to syngas into syngas, b) using the syngas in a Fischer-Tropsch reaction using a catalyst with low chain growth probabilities to obtain a product stream that includes C_2-4 olefins and C_2-4 paraffins, c) isolating the C_2-4 olefins, or a desired portion thereof, optionally in combination with C_2-4 paraffins, or a portion thereof, and d) polymerizing the isolated olefins or portion thereof.

13. The process of claim 12, wherein the polymer formed during the polymerization step is polyethylene, polypropylene, polybutene, or a co-polymer or terpolymer thereof.

14. The process of claim 12, wherein the renewable resource is selected from the group consisting of glycerol, methanol, lignin, black liquor, switchgrass, bagasse, corn stover, rice hulls, sawdust, wood, hemicellulose, and algae.

15. The process of claim 12, wherein at least a portion of the C_2-4 paraffins, or a fraction thereof, is dehydrogenated to form olefins.

16. The process of claim 15, further comprising isolating propylene from the dehydrogenated C_2-4 paraffins.

17. The process of claim 15, wherein at least a portion of the resulting olefins are subjected to olefin metathesis to form propylene, further comprising isolating the propylene.

18. The process of claim 12, further comprising polymerizing the propylene to form polypropylene.

19. The process of claim 12, further comprising copolymerizing the propylene with another monomer to form a polypropylene copolymer.

20. The process of claim 19, wherein the other monomer is selected from the group consisting of ethylene, butylene, maleic acid, and furan.

21. The process of claim 12, wherein the polymerization is performed using a Ziegler-Natta catalyst.

22. The process of claim 12, wherein the polymerization is performed using a metallocene catalyst.

23. (canceled)